Integrated inlet design

Abstract

A nacelle assembly and a method for assembling the same is provided. The nacelle assembly includes an inner barrel and an outer structure comprising a highlight and an outer aft section, wherein the highlight is defined by a forward end of the outer structure, wherein the outer aft section includes a point defined by a maximum diameter of the nacelle assembly, wherein the nacelle assembly extends at least between the highlight and the point.

What is claimed is: 
     
       1. A method for assembling a nacelle assembly, said method comprising:
 providing an outer structure that extends at least between a highlight defined by a forward end of the outer structure and a point defined by a maximum diameter of the nacelle assembly; 
 coupling a structural foam to an inner surface of an outer aft section of the outer structure; and 
 coupling the outer structure to an inner barrel. 
 
     
     
       2. A method for assembling a nacelle assembly in accordance with  claim 1 , wherein said providing an outer structure further comprises:
 providing an outer structure that is fabricated from at least one of a continuous fiber reinforced thermoplastic material and a continuous fiber reinforced thermoset material. 
 
     
     
       3. A method for assembling a nacelle assembly in accordance with  claim 1 , wherein coupling the outer structure further comprises:
 coupling the outer structure to an inner barrel, wherein the outer structure includes a first flange that is positioned at an inner aft section of the outer structure, wherein the first flange is configured to couple the outer structure to the inner barrel. 
 
     
     
       4. A method for assembling a nacelle assembly in accordance with  claim 1  further comprising:
 coupling the outer structure to a fan case, wherein the outer structure includes a second flange that is positioned at an inner aft section of the outer structure, wherein the second flange is configured to couple to the outer structure to the fan case. 
 
     
     
       5. A method for assembling a nacelle assembly in accordance with  claim 1 , wherein said providing an outer structure further comprises:
 providing an outer structure that includes a stiffener that is positioned at the inner surface of the outer aft section, wherein the stiffener is configured to structurally support the outer structure. 
 
     
     
       6. A method for assembling a nacelle assembly in accordance with  claim 1  further comprising:
 providing at least one of a stiffener and a bulkhead that is configured to structurally support the outer structure; and 
 coupling the at least one of the stiffener and the bulkhead to the inner surface of the outer aft section via at least one of thermoplastic welding and adhesive bonding. 
 
     
     
       7. An outer structure of a nacelle assembly, said outer structure comprising:
 a highlight defined by a forward end of said outer structure; 
 an outer aft section that includes a point defined by a maximum diameter of said nacelle assembly, wherein said nacelle assembly extends at least between said highlight and said point; and 
 a structural foam coupled to an inner surface of said outer aft section, said structural foam configured to structurally support said outer structure. 
 
     
     
       8. An outer structure in accordance with  claim 7 , wherein said outer structure is fabricated from at least one of a continuous fiber reinforced thermoplastic material and a continuous fiber reinforced thermoset material. 
     
     
       9. An outer structure in accordance with  claim 7  further comprising a first flange that is positioned at an inner aft section of said outer structure, said first flange configured to couple said outer structure to an inner barrel. 
     
     
       10. An outer structure in accordance with  claim 7  further comprising a second flange that is positioned at an inner aft section of said outer structure, said second flange configured to couple said outer structure to a fan case. 
     
     
       11. An outer structure in accordance with  claim 7  further comprising a stiffener that is positioned at the inner surface of said outer aft section, wherein said stiffener is configured to structurally support said outer aft section. 
     
     
       12. An outer structure in accordance with  claim 7  further comprising at least one of a stiffener and a bulkhead that is configured to structurally support said outer structure, wherein at least one of the stiffener and the bulkhead is coupled to the inner surface of said outer aft section via at least one of thermoplastic welding and adhesive bonding. 
     
     
       13. A nacelle assembly comprising:
 an inner barrel; and 
 an outer structure comprising a highlight and an outer aft section, wherein said highlight is defined by a forward end of said outer structure, wherein said outer aft section includes a point defined by a maximum diameter of said nacelle assembly, wherein said nacelle assembly extends at least between said highlight and said point, and wherein a structural foam is coupled to an inner surface of said outer aft section. 
 
     
     
       14. A nacelle assembly in accordance with  claim 13 , wherein said outer structure is fabricated from at least one of a continuous fiber reinforced thermoplastic material and a continuous fiber reinforced thermoset material. 
     
     
       15. A nacelle assembly in accordance with  claim 13  further comprising a first flange that is positioned at an inner aft section of said outer structure, said first flange configured to couple said outer structure to an inner barrel. 
     
     
       16. A nacelle assembly in accordance with  claim 13  further comprising a second flange that is positioned at an inner aft section of said outer structure, said second flange configured to couple said outer structure to a fan case. 
     
     
       17. A nacelle assembly in accordance with  claim 13 , wherein said outer structure further comprises a stiffener that is positioned at the inner surface of said outer aft section, wherein said stiffener is configured to structurally support said outer aft section. 
     
     
       18. A nacelle assembly in accordance with  claim 13  further comprising a stiffener that is configured to structurally support said outer structure, wherein the stiffener is coupled to the inner surface of said outer aft section via at least one of thermoplastic welding and adhesive bonding. 
     
     
       19. A nacelle assembly in accordance with  claim 13  further comprising a bulkhead that is configured to structurally support said outer structure, wherein the bulkhead is coupled to the inner surface of said outer aft section via at least one of a mechanical fastening process, a thermoplastic welding process, and an adhesive bonding process. 
     
     
       20. A nacelle assembly in accordance with  claim 13  wherein the structural foam is configured to structurally support said outer structure, and wherein the structural foam is coupled to the inner surface of said outer aft section via at least one of thermoplastic welding and adhesive bonding.